STARTER SYSTEM TESTING 5.6

STARTER SYSTEM TESTING 5.6 ON-MOTORCYCLE TESTS Starter Relay Test NOTE Starter relay test also applies to ignition and key switch relays.. See Figure 5-5. Locate starter relay. The relay is attached to the relay block under the seat.. To test relay, proceed to Step. If installing a new starter relay, remove old relay. Install new relay into relay block.. See Figure 5-6. Obtain a volt battery and a continuity tester or ohmmeter. a. Pull relay from relay block. b. Connect positive battery lead to the terminal. c. Connect negative battery lead to the terminal to energize relay. d. Check for continuity between the and 5 terminals. A good relay shows continuity (continuity tester lamp on or a zero ohm reading on the ohmmeter). A malfunctioning relay will not show continuity and must be replaced. 4. If starter relay is functioning properly, proceed to STARTER CURRENT DRAW TEST. bxx 4 6 7 8 9 0 5 4 5 6. Spare (0 Amp). Spare (5 Amp). Fan (0 Amp) 4. Brake/horn/interactive exhaust (0 Amp) 5. Accessory (0 Amp) 6. Ignition (5 Amp) 7. Key switch (5 Amp) 8. Lamps (5 Amp) 9. ECM (0 Amp) 0. Battery (0 Amp). AUX (0 Amp). Diode. Key switch relay 4. Ignition relay 5. AUX relay 6. Start relay Figure 5-5. Fuses, Relays and Diode 007 Buell Ulysses: Starter 5-

Starter Current Draw Test NOTES Engine temperature should be stable and at room temperature. Battery should be fully charged. See Figure 5-7. Check starter current draw with an induction ammeter before disconnecting battery. Proceed as follows:. Verify that transmission is in neutral. Disconnect spark plug wires from spark plug terminals.. Clamp induction ammeter over positive battery cable next to starter.. With ignition key switch ON, turn engine over by pressing starter switch while taking a reading on the ammeter. Disregard initial high current reading which is normal when engine is first turned over. a. Typical starter current draw will range between 40-80 amperes. b. If starter current draw exceeds 80 amperes, then the problem may be in the starter or starter drive. Remove starter for further tests. See 5.7 STARTER. b0755a5x b060x5x Battery 86 87A 87 0 85 Figure 5-6. Starter Relay Test Induction Ammeter Ohmmeter Battery Figure 5-7. Starter Draw Test 5-007 Buell Ulysses: Starter

STARTER 5.7 REMOVAL b0x5x. Remove seat. See.45 SEAT. WARNING Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a). Disconnect battery. See.4 BATTERY MAINTENANCE.. Remove primary cover. See 6. PRIMARY COVER. 4. Remove sprocket cover. See.5 SPROCKET COVER.. Mounting bolts and washers. Starter Figure 5-8. Starter Mounting NOTE A ball hex driver may be required to gain access to the starter mounting bolts. 5. See Figure 5-8. Remove two starter mounting bolts and washers (). 6. See Figure 5-9. Remove fastener with washer () (metric). a. Remove protective boot. b. Remove positive battery cable ring terminal (). c. Detach solenoid wire (). 7. Remove starter and gasket from the gearcase cover side. 67 874. Fastener with washer (metric). Positive battery cable ring terminal. Solenoid wire Figure 5-9. Starter Wires (Protective Boot Not Shown) 007 Buell Ulysses: Starter 5-

TESTING ASSEMBLED STARTER b049x5x Free Running Current Draw Test. Place starter in vise, using a clean shop towel to prevent scratches or other damage. 5. See Figure 5-0. Attach one heavy jumper cable (6 gauge minimum). a. To the starter mounting flange (). b. To the negative (-) terminal of a fully charged battery.. Connect a second heavy jumper cable (6 gauge minimum). a. To the positive (+) terminal of the battery ().. Mounting flange. Battery. Induction ammeter 4. Battery terminal 5. Relay terminal 4 b. To an inductive ammeter (). Continue on to the battery terminal (4) on the starter solenoid. Figure 5-0. Free Running Current Draw Test 4. Connect a smaller jumper cable (4 gauge minimum). a. To the positive (+) terminal of the battery (). b. To the solenoid relay terminal (5). 5. Check ammeter reading. a. Ammeter should show 90 amps maximum. b. If reading is higher, disassemble starter for inspection. See 5.7 STARTER. c. If starter current draw on vehicle was over 00 amps and this test was within specification, there may be a problem with engine or primary drive. Starter Solenoid b06a5x Motor terminal Relay terminal Battery NOTES Do not disassemble solenoid. Before testing, disconnect field wire from motor terminal as shown in Figure 5-. Figure 5-. Pull-In Test Each test should be performed for only -5 seconds to prevent damage to solenoid. The solenoid Pull-in, Hold-in, and Return tests must be performed together in one continuous operation. Conduct all three tests one after the other in the sequence given without interruption. Solenoid Pull-in Test. See Figure 5-. Using a volt battery, connect three separate test leads as follows: a. Solenoid housing to negative battery post. b. Solenoid motor terminal to negative battery post. c. Solenoid relay terminal to positive battery post.. Observe starter pinion. a. If starter pinion pulls in strongly, solenoid is working properly. b. If starter pinion does not pull in, replace the solenoid. 5-4 007 Buell Ulysses: Starter

Solenoid Hold-in Test. See Figure 5-. With test leads still connected in the manner specified in the previous SOLENOID PULL-IN TEST, disconnect solenoid motor terminal/battery negative test lead (B) at negative battery post only; reconnect loose end of this test lead to positive battery post instead.. Observe starter pinion. a. If starter pinion remains in pull-in position, solenoid is working properly. b. If starter pinion does not remain in pull-in position, replace the solenoid. Solenoid Return Test b06a5x Motor terminal Relay terminal Battery. See Figure 5-. With test leads still connected in the manner specified at the end of the previous SOLENOID HOLD-IN TEST, disconnect solenoid relay terminal/ positive battery post test lead (C) at either end.. Observe starter pinion. a. If starter pinion returns to its original position, solenoid is working properly. b. If starter pinion does not return to its original position, replace the solenoid. b06a5x Figure 5-. Hold-In Test Motor terminal Relay terminal Battery Figure 5-. Return Test 007 Buell Ulysses: Starter 5-5

DISASSEMBLY, INSPECTION AND REPAIR 6007. See Figure 5-4. Lift rubber boot (). Remove field wire nut with washer () (metric) to detach field wire ().. See Figure 5-5. Remove both thru-bolts (, ).. Remove both end cover screws with O-rings () and end cover (4). 4. See Figure 5-6. Use a wire hook to pull upward on brush springs (), and lift brushes out of holder (). Remove brush holder. 5. Check brush length. Replace all four brushes if length of any one brush is less than 0.4 in. (.0 mm).. Rubber boot. Field wire nut with washer (metric). Field wire Figure 5-4. Field Wire NOTE Brushes not available separately. Purchase a new field frame () and brush holder () to replace brushes. 6009 6. Remove armature (4) and field frame (). 7. Place armature in lathe or truing stand and check commutator runout and diameter. 4 a. Commutators with more than 0.06 in. (0.406 mm) of runout should be replaced or machined on a lathe. b. Replace commutators when diameter is less than.4 in. (8.98 mm). c. Check armature bearings. Replace if necessary. NOTES. Lower thru-bolt. Screw with O-ring (). Upper thru-bolt 4. End cover Figure 5-5. Removing the Thru-Bolts Do not use sandpaper or emery cloth to remove burrs on commutator. Otherwise, abrasive grit may remain on commutator segments; this could lead to excessive brush wear. Use only the recommended crocus cloth. 600 See Figure 5-7. If an undercutting machine is not available, undercutting can be done satisfactorily using a thin hacksaw blade. After undercutting, lightly sand the commutator with crocus cloth to remove any burrs. 8. Check depth of mica on commutator. If undercut is less than 0.008 in. (0.0 mm), use an undercutting machine to undercut the mica to / in. (0.794 mm) deep. The slots should then be cleaned to remove any dirt or copper dust. 5 4. Field frame. Brush holder. Brush spring (4) 4. Armature 5. Solenoid housing Figure 5-6. Starter Components 5-6 007 Buell Ulysses: Starter

b06x5x Starting groove in mica with cornered file Segments Mica must not be left with a thin edge next to segments Mica WRONG WAY Undercutting mica with piece of hacksaw blade Mica must be cut away clean between segments Segments Mica Figure 5-7. Undercutting Mica Separators RIGHT WAY 007 Buell Ulysses: Starter 5-7

9. See Figure 5-8. Check for SHORTED ARMATURE with a growler. a. Place armature on growler (). b. Hold a thin steel strip () (hacksaw blade) against armature core and slowly turn armature. c. A shorted armature will cause the steel strip to vibrate and be attracted to the core. Replace shorted armatures. 0. See Figure 5-9. Check for a GROUNDED ARMATURE with an ohmmeter or continuity tester. a. Touch one probe to any commutator segment (). b. Touch the other probe to the armature core (). c. There should be no continuity (infinite ohms). If there is continuity, then the armature is grounded. Replace grounded armatures.. See Figure 5-0. Check for OPEN ARMATURE with an ohmmeter or continuity tester. a. Check for continuity between all commutator segments (). b. There should be continuity (0 ohms) at all test points. No continuity at any test point indicates armature is open and must be replaced. 78a Figure 5-8. Shorted Armature Test Using Growler 60 Figure 5-9. Grounded Armature Test 60a Figure 5-0. Open Armature Test 5-8 007 Buell Ulysses: Starter

. See Figure 5-. Check for GROUNDED FIELD COIL with an ohmmeter or continuity tester. a. Touch one probe to the frame (). b. Touch the other probe to each of the brushes () attached to the field coil. c. There should be no continuity (infinite ohms). If there is any continuity at either brush, then the field coil(s) are grounded and the field frame must be replaced.. See Figure 5-. Check for OPEN FIELD COILS with an ohmmeter or continuity tester. a. Touch one probe to the field wire (). b. Touch the other probe to each of the brushes attached to the field coil(s) (). c. There should be continuity (0 ohms). If there is no continuity at either brush, then the field coil(s) are open and the field frame must be replaced. 4. See Figure 5-. Test BRUSH HOLDER INSULATION with an ohmmeter or continuity tester. a. Touch one probe to holder plate (). b. Touch the other probe to each of the positive (insulated) brush holders (). c. There should be no continuity (infinite ohms). If there is continuity at either brush holder, replace the brush holder assembly. 5. See Figure 5-4. Remove two drive housing mounting screws (6). Remove drive housing (5) from solenoid housing. 6. Remove drive (), idler gear (), idler gear bearing (), and o-ring (4) from drive housing (o-ring is located in drive housing groove). 60a 604a Figure 5-. Grounded Field Test Figure 5-. Open Field Test s064x5x Figure 5-. Brush Holder Insulation Test 007 Buell Ulysses: Starter 5-9

ASSEMBLY. See Figure 5-4. Clean, inspect and lubricate drive assembly components. Lubricate parts with high temperature grease, such as LUBRIPLATE 0.. See Figure 5-7. When installing drive assembly components, open end of idler bearing cage (5) faces toward solenoid.. When installing drive housing (0) to solenoid housing (), use new O-ring (6). Be sure to install return spring (7) and ball (8). 4. Lubricate armature bearings (8) with high temperature grease, such as LUBRIPLATE 0. Install armature (6) and field frame (7) to solenoid housing (). 5. Install brushes and brush holder (4). 6. Install O-rings (). Attach end cover () with end cover screws and O-rings (). 7. Install thru-bolts (). 8. Attach field wire () to solenoid housing () with field wire nut and washer (4) (metric). Replace rubber boot. INSTALLATION. Install starter and starter gasket from the gearcase cover side.. See Figure 5-5. Connect wiring to starter. a. Connect solenoid wire (). b. Attach positive battery cable ring terminal () to stud with fastener and washer. c. Install nut and washer () (metric). Tighten nut to 60-85 in-lbs (7-0 Nm). d. Reinstall existing protective boot.. See Figure 5-6. Install both starter mounting bolts and washers. Tighten to -0 ft-lbs (8-7 Nm). 4. Install sprocket cover. See.5 SPROCKET COVER. 5. Install primary cover. See 6. PRIMARY COVER. WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) 6. Install positive battery cable (red) to positive terminal of battery. Tighten to 7-96 in-lbs (8- Nm). 7. Connect negative battery cable. Tighten to 7-96 in-lbs (8- Nm). 607. Drive. Idler gear. Idler gear bearing 67 Figure 5-4. Starter Drive Assembly 4 5 4. O-Ring 5. Drive housing 6. Screws. Fastener with washer (metric). Positive battery cable ring terminal. Solenoid wire Figure 5-5. Starter Wires (Protective Boot Not Shown) 6 b0x5x WARNING After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 8. Install seat. See.45 SEAT.. Mounting bolts and washers. Starter Figure 5-6. Starter Mounting 5-0 007 Buell Ulysses: Starter

b0004a5x 5 4 7 4 8 6 8 5 4 7 8 6 9 0 0 9. Thru-bolt (). End cover screw and o-ring (). End cover 4. Brush holder 5. Brush spring (4) 6. Armature 7. Field frame 8. Armature bearing () 9. Drive housing mounting bolt 0. Drive housing. Solenoid housing. Drive assembly/overrunning clutch. Idler gear 4. Idler gear roller (5) 5. Idler gear bearing cage 6. O-ring 7. Return spring 8. Ball 9. Gasket 0. Washer (). Mounting bolt (). Field wire. O-ring () 4. Field wire nut with washer (metric) Figure 5-7. Starter Assembly 007 Buell Ulysses: Starter 5-

STARTER SOLENOID 5.8 GENERAL b058x5x NOTE See Figure 5-8. Do not tighten nut (7) without removing items -5. Movement will cause damage to the contact. The starter solenoid is a switch that is designed to open and close the starting circuit electromagnetically. The switch consists of contacts and a winding around a hollow cylinder containing a movable plunger. DISASSEMBLY 6 5 7 4. See Figure 5-8. Remove screws () and clip ().. Remove cover () and gasket (4). Discard gasket.. Remove plunger (5) from solenoid housing (6). ASSEMBLY. See Figure 5-8. Replace wire connection hardware as necessary.. Install plunger (5) in solenoid housing (6).. Install new gasket (4) onto cover (). 4. Position cover with gasket onto solenoid housing. Install clip () and screws ().. Screw (). Clip. Cover 4. Gasket 5. Plunger 6. Solenoid housing 7. Nut Figure 5-8. Starter Solenoid 5-007 Buell Ulysses: Starter